2012-12-06 | Forming

OCMI-OTG, a global leader in the field of machinery for the production of tubular glassware, presents, in this article, its most recent developments for one of the most demanding areas of the glass industry – the pharmaceutical sector.

OCMI's FLA continuous rotary forming machine for vial production

With three manufacturing plants: in Italy (OCMI headquarters), France (Moderne Mecanique) and India (OCMI India), and a total of more than 100 employees, OCMI Group is globally recognized today as a leading supplier and technical partner for the manufacturers of pharmaceutical containers.Particularly in the ampoules production sector, OCMI can combine its experience and know-how with the considerable knowledge regarding glass tube processing of Moderne Mecanique, its French manufacturing unit, not far from Paris, purchased by OCMI in 1998 from the Schott Group.OCMI and Moderne Mecanique are able to offer a wide range of solutions for ampoules and vials production from glass tube, and are specialized in continuous rotary forming machines to be connected with complementary after-forming lines.In addition to its official production plants, OCMI also has a Training Center in Egypt, in the factory of its partner European Ampoules Co., equipped with eight ampoule lines and one vial line, where new manufacturers of vials/ampoules can get a precise idea about technology, raw materials, utilities, and even the man-power needed to set up a tubular glass container factory, exclusive to the pharmaceutical sector.

AmpoulesConfirming OCMI’s reputation in the worldwide market, the manufacture of the 1,000th machine of the MM-30 30-station ampoule former was celebrated at the Moderne Mecanique plant in January this year. Thanks to its sturdy construction and ease of operations, this machine c...

With three manufacturing plants: in Italy (OCMI headquarters), France (Moderne Mecanique) and India (OCMI India), and a total of more than 100 employees, OCMI Group is globally recognized today as a leading supplier and technical partner for the manufacturers of pharmaceutical containers.Particularly in the ampoules production sector, OCMI can combine its experience and know-how with the considerable knowledge regarding glass tube processing of Moderne Mecanique, its French manufacturing unit, not far from Paris, purchased by OCMI in 1998 from the Schott Group.OCMI and Moderne Mecanique are able to offer a wide range of solutions for ampoules and vials production from glass tube, and are specialized in continuous rotary forming machines to be connected with complementary after-forming lines.In addition to its official production plants, OCMI also has a Training Center in Egypt, in the factory of its partner European Ampoules Co., equipped with eight ampoule lines and one vial line, where new manufacturers of vials/ampoules can get a precise idea about technology, raw materials, utilities, and even the man-power needed to set up a tubular glass container factory, exclusive to the pharmaceutical sector.

AmpoulesConfirming OCMI’s reputation in the worldwide market, the manufacture of the 1,000th machine of the MM-30 30-station ampoule former was celebrated at the Moderne Mecanique plant in January this year. Thanks to its sturdy construction and ease of operations, this machine can, says OCMI, surely be considered the best ampoule forming machine available in the market today.The alternative model for this kind of operation, OCMI’s FA-36S 36-station machine, is equipped with a special section for tube bottom forming, in order to reduce glass waste and save approximately five per cent of glass at the end of working day.Both forming machines have a maximum gross production of 4,500 pieces per hour, depending on ampoule characteristics and on the operations to be carried out on the after-forming line.Ampoule forming linesOCMI’s LA ampoule after-forming line can be equipped with standard or optional devices to manufacture any kind of product according or not to ISO specifications.Moderne Mecanique lines are able to apply a maximum of three identification rings, in addition to colour break, or OPC cutting.A Form-D closing device is also available with or without air cooling. When installed before the ampoule closing system, this optional device enables to create positive pressure in the ampoule and to expel the glass particles during filling operations.After the annealing lehr, the line is available in U-shape or straight configuration: this second option purposely studied for companies with packing operations carried out in cleanroom environments.

VialsOCMI has two types of continuous rotary forming machines for vial production. These are the FLA-20 and FLA-35 with, respectively, 20 and 35 stations.The FLA-35 machine is equipped with a very special finishing tooling section, completely independent from the main body of the machine, in order to facilitate maintenance.Both machines are equipped with pre-forming heads to prepare the shoulders and the glass quantity to be processed prior to the finishing station. Sets of rollers and plungers for pre-tooling and finishing heads are prepared and supplied by OCMI according to the vials to be manufactured.Vial forming machines can work with glass tubes from 8 to 30 millimetres in diameter and maximum vial height of 150 millimetres.The FLA-20 smaller model can reach maximum productivity of 2,800/3,000 vials in the case of really small formats, while the FLA-35 can reach maximum productivity of 4,500 vials per hour.Also in this case, both machines can be connected with complementary after-forming lines, which can be equipped with a maximum of four dimensional control stations, and printing station with pre-drying oven, prior to the annealing lehr.TAM-16 is the 16-station vial forming machine with index technology that is produced in the manufacturing unit of OCMI India in Ahmenabad.

Camera quality control systemA camera quality control system can be installed on both vial and ampoule forming machines. In particular, the OPTISTEM/2 system, installed on MM-30 or FA-36S ampoule forming machines, enables to adjust stem quality in real time by means of the automatic regulation of the oxygen level in the two pre-forming burners. This, in turn, results in much more efficiency in terms of raw material consumption.

PackingIn the last few years, the group has invested considerable financial and human resources in the continuous improvement of machine performance and after-sales assistance, guaranteeing the quality required by the market and establishing long and profitable relationships with customers.

Automatic ampoule packingIn order to satisfy really important demands of the market, OCMI recently developed the new PM-A automatic ampoule packing machine studied and developed to be connected first and foremost with after-forming lines made by Moderne Mecanique, but also with lines produced by different manufacturers through an already available interface.This new machine allows to pick up the glass ampoules from the chain of the production line and transfer them automatically into the boxes by means of vacuum cups. This system solves the continuous problem of friction between ampoules during traditional box filling operations. Furthermore, the operator is absolutely sure to have the correct number of ampoules in each box and has enough time for unloading operations since there are four boxes waiting on the rotating table. In this way, each operator is able to control more than one packing station.The transfer system from the production line chain to the packing machine depends on the type of production line used: the packing machine can be positioned on both sides of the production line, according to the space available in the factory and according to the operator’s way of working.The PM-A packing machine can, as an option, be equipped with an ampoule overturning device.The packing machine chain is equipped with a sensor detecting the missing ampoules on the conveyor of the production line. This sensor ensures that the ampoules are picked up in complete lines, without leaving any empty position in the box.Manual operations for adjustments and job changes are executed by means of the touchscreen. Available functions include: picking simulation, counter of packed units and completed boxes, and partial or total amounts of picked units, jobs parameters storage, set of numbers of ampoules per row, set of rows configuration.A sensor sends a signal to a lamp, also launching an acoustic signal in order to inform the operator that he must unload at least one filled box, while another one detects the missing units on the chain of production line and stops the V-chain of the packing machine. This enables to always have full lines of ampoules on the V-chain of the packing machine and in the boxes too.Light and acoustic signals indicate the working status of the machine and advise when the rotating table is moving. The few uncovered parts of the picking system are equipped with security cables with safety micro-switches. Emergency buttons are located along the machine perimeter in order to stop the machine if needed.